RADIATOR CAPS DIVISION

SUNDRAM FASTENERS LTD

JOB CHANGE TIME REDUCTION ON THE

PLATARG PRESS
PROBLEM DEFINITION
PROBLEM : The Job Change is consuming
a lot of time in the Platarg Press.

PRESENT LEVEL : The process time taken is

234 mins (51085529)

TARGET LEVEL : 180 mins.

TEAM MEMBERS
1. Suhas Nair (Team Leader)
2. Abishek B K (Team Member)
3. Mohamed Nizar (Team member)
RELEVANCE OF THE PROBLEM
The Platarg Press is the most important machine for
the metal cap assembly line
Bottleneck in the metal cap assembly
Hence a reduction in the job change time will lead to
better OEE .
This explains the need for the analysis of this problem
 Problem
Conclusion
Observation

Standardization Analysis
A P
C D

Check Action
S . No. INTERNAL ACTIVITIES TIME TAKEN % Cumulative %

1 Trans Probe Sensors removed (6 sensors) 1 0.43 0.43

2 Transfer rails removed 4 1.71 2.14
3 Blanking sheet feeder support removed 1 0.43 2.56

4 Festo Feeder moved 3 1.28 3.85

5 Blanking to forming job transfer plate removed 1 0.43 4.27
6 scratch proofing stickers removed 3 1.28 5.56
7 forming tool holder &transprobe holder removed 1 0.43 5.98

8 Ram load released 3 1.28 7.26

9 Blanking tool top screws removed 4 1.71 8.97
10 Blanking tool bottom crews removed 2 0.85 9.83

11 Ram brought to bottom position 0 0.00 9.83

12 Blanking tool moved to pre-qualification table 6 2.56 12.39
13 Dismantling the removed tool 25 10.68 23.08
14 Bottom die holding screw of forming tool removed 3 1.28 24.36
15 Top tool holding screw removed 3 1.28 25.64
16 Tool moved to rack and newtool fixed 30 12.82 38.46
17 Ram moved to top Position 0 0.00 38.46

18 Clapping tool changed on the machine 5 2.14 40.60

19 Forming tool disassembled and new assembled 75 32.05 72.65
20 Blanking tool moved onto machine 2 0.85 73.50
21 Bottom screws tightened 10 4.27 77.78
22 Ram brought back to top position 0 0.00 77.78
23 Forming tool moved onto machine 5 2.14 79.91
24 Forming tool fixed onto machine 7 2.99 82.91
25 Marking tool changed on the machine itself 4 1.71 84.62
26 Piercing tool hanged on the machine 4 1.71 86.32

27 Festo feeder moved back to position 5 2.14 88.46

28 Marking die prepared 1 0.43 88.89
29 Marking die fixed 1 0.43 89.32
30 Test Run 15 6.41 95.73

31 Feeder, rails , transpobes fixed on 10 4.27 100.00

    234 100.00  
 100.00

Job Change Time Paretto

90.00

80.00

70.00

60.00

50.00
%

40.00

30.00

20.00

10.00

0.00

Activities
 CAUSE AND EFFECT- LEVEL DIAGRAM
MAN MACHINE
Single person Complex operations

Hi- stacker availability Unscrewing bottom screw

cumbersome
Operator fatigue
JOB CHANGE
HOUSING
TIME
CRACK
Hi-stacker bulky No standardized
procedure
No proper tools
Dismantling of
tools

MATERIAL METHOD
 CAUSE & EFFECT- LEVEL 2
• Standardized procedure not followed
• No proper tools for dismantling M/C tool
• Tool mover (Hi-stacker M/C) too bulky